1999 SUBARU LEGACY lock

Cylinder
headSurface warpage limit 0.05 mm (0.0020 in)
Surface grinding limit 0.3 mm (0.012 in)
Standard height 97.5 mm (3.839 in)
Valve
setRefacing angle 90É
Contacting widthIntakeSTD 1.0 mm (0.039 in)
Limit 1.7 mm (0.067 in)
ExhaustSTD 1.4 mm (0.055 in)
Limit 2.1 mm (0.083 in)
Valve
guideInner diameter 6.000 Ð 6.012 mm (0.2362 Ð 0.2367 in)
Protrusion above headIntake 20.0 Ð 20.5 mm (0.787 Ð 0.807 in)
Exhaust 16.5 Ð 17.0 mm (0.650 Ð 0.669 in)
ValveHead edge thicknessIntakeSTD 1.0 mm (0.039 in)
Limit 0.6 mm (0.024 in)
ExhaustSTD 1.2 mm (0.047 in)
Limit 0.6 mm (0.024 in)
Stem diameterIntake 5.945 Ð 5.960 mm (0.2341 Ð 0.2346 in)
Exhaust 5.950 Ð 5.965 mm (0.2343 Ð 0.2348 in)
Stem oil clearanceSTDIntake 0.035 Ð 0.062 mm (0.0014 Ð 0.0024 in)
Exhaust 0.040 Ð 0.067 mm (0.0016 Ð 0.0026 in)
Limit Ð 0.15 mm (0.0059 in)
Overall lengthIntake 120.6 mm (4.75 in)
Exhaust 121.7 mm (4.79 in)
Valve
springFree length 54.30 mm (2.1378 in)
Squareness 2.5É, 2.4 mm (0.094 in)
Tension/spring height214.8 Ð 246.2 N
(21.9 Ð 25.1 kg, 48.3 Ð 55.3 lb)/45.0 mm (1.772 in)
526.6 Ð 581.6 N
(53.7 Ð 59.3 kg, 118.4 Ð 130.8 lb)/34.7 mm (1.366 in)
Cylinder
blockSurface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
Surface grinding limit 0.1 mm (0.004 in)
Cylinder bore STDA 96.905 Ð 96.915 mm (3.8151 Ð 3.8155 in)
B 96.895 Ð 96.905 mm (3.8148 Ð 3.8151 in)
TaperSTD 0.015 mm (0.0006 in)
Limit 0.050 mm (0.0020 in)
Out-of-roundnessSTD 0.010 mm (0.0004 in)
Limit 0.050 mm (0.0020 in)
Piston clearanceSTD 0.010 Ð 0.030 mm (0.0004 Ð 0.0012 in)
Limit 0.050 mm (0.0020 in)
Enlarging (boring) limit 0.5 mm (0.020 in)
Piston Outer diameterSTDA 96.885 Ð 96.895 mm (3.8144 Ð 3.8148 in)
B 96.875 Ð 96.885 mm (3.8140 Ð 3.8144 in)
0.25 mm (0.0098
in) OS97.125 Ð 97.135 mm (3.8238 Ð 3.8242 in)
0.50 mm (0.0197
in) OS97.375 Ð 97.385 mm (3.8337 Ð 3.8340 in)
Piston
pinStandard clearance between piston
pin and hole in pistonSTD 0.004 Ð 0.008 mm (0.0002 Ð 0.0003 in)
Limit 0.020 mm (0.0008 in)
Degree of fitPiston pin must be fitted into position with thumb at 20ÉC
(68ÉF).
3
[S1B0]2-3aSPECIFICATIONS AND SERVICE DATA
1. Engine

4. Cylinder Block
B2M1957A
(1) Oil pressure switch
(2) Cylinder block (RH)
(3) Service hole plug
(4) Gasket
(5) Oil separator cover
(6) Water by-pass pipe
(7) Oil pump
(8) Front oil sea
(9) Rear oil seal
(10) O-ring
(11) Service hole cover(12) Cylinder block (LH)
(13) Water pump
(14) Baffle plate
(15) Oil filter connector
(16) Oil strainer
(17) Gasket
(18) Oil pan
(19) Drain plug
(20) Metal gasket
(21) Oil level gauge guideTightening torque: N´m (kg-m, ft-lb)
T1:
5 (0.5, 3.6)
T2:6.4 (0.65, 4.7)
T3:10 (1.0, 7)
T4:25±2 (2.5±0.2, 18.1±1.4)
T5:47±3 (4.8±0.3, 34.7±2.2)
T6:69±7 (7.0±0.7, 50.6±5.1)
T7:First 12±2 (1.2±0.2, 8.7±1.4)
Second 12
±2 (1.2±0.2,
8.7
±1.4)
9
[C400]2-3aCOMPONENT PARTS
4. Cylinder Block

2. Timing Belt
A: REMOVAL
1. CRANKSHAFT PULLEY AND BELT COVER
B2M2583A
(1) Front side V-belt
(2) Rear side V-belt (With A/C
model)(3) Crankshaft pulley bolt
(4) Crankshaft Pulley
(5) Belt cover (LH)(6) Front belt cover
1) Remove A/C belt. (With A/C model)
B2M2584
2) Remove A/C belt tensioner. (With A/C model)
B2M2585
3) Remove crankshaft pulley bolt. To lock
crankshaft, use ST.
ST 499977000 CRANKSHAFT PULLEY
WRENCH
B2M2586A
4) Remove crankshaft pulley.
13
[W2A1]2-3aSERVICE PROCEDURE
2. Timing Belt

4. CAMSHAFT AND CRANKSHAFT SPROCKET
B2M2598B
(1) Camshaft sprocket No. 2
(2) Camshaft sprocket No. 1
(3) Crankshaft sprocket (California
spec. vehicles)(4) Belt cover No. 2 (LH)
(5) Belt cover No. 2 (RH)
(6) Tensioner bracket
1) Remove camshaft sprocket No. 2. To lock
camshaft, use ST.
ST 499207100 CAMSHAFT SPROCKET
WRENCH
H2M2377A
2) Remove camshaft sprocket No. 1. To lock
camshaft, use ST.
ST 499207400 CAMSHAFT SPROCKET
WRENCH
B2M2599A
17
[W2A4]2-3aSERVICE PROCEDURE
2. Timing Belt

1) Install tensioner bracket.
H2M2380
2) Install belt cover No. 2 (RH).
3) Install belt cover No. 2 (LH).
B2M2601
4) Install crankshaft sprocket.
B2M2600A
S2M0414A
5) Install camshaft sprocket No. 1. To lock
camshaft, use ST.
ST 499207400 CAMSHAFT SPROCKET
WRENCH
B2M2599A
6) Install camshaft sprocket No. 2. To lock
camshaft, use ST.
ST 499207100 CAMSHAFT SPROCKET
WRENCH
CAUTION:
Do not confuse left and right side camshaft
sprockets during installation. The camshaft
sprocket No. 2 is identified by a projection
used to monitor camshaft position sensor.
H2M2377A
20
2-3a[W2C1]SERVICE PROCEDURE
2. Timing Belt

4. CRANKSHAFT PULLEY AND BELT COVER
B2M2583B
(1) Front belt cover
(2) Belt cover (LH)
(3) Crankshaft pulley
(4) Crankshaft pulley bolt(5) Rear side V-belt (With A/C
model)
(6) Front side V-beltTightening torque: N´m (kg-m, ft-lb)
T1:
5±1 (0.5±0.1, 3.6±0.7)
T2:127+10/þ5(13.0+1.0/þ0.5,
94+7.2/þ3.6)
1) Install front belt cover.
2) Install belt cover (LH).
B2M2587A
3) Install crankshaft pulley.
4) Install pulley bolt.
To lock crankshaft, use ST.
ST 499977000 CRANKSHAFT PULLEY
WRENCH
(1) Clean the crankshaft pulley thread using an
air gun.
(2) Apply engine oil to the crankshaft pulley bolt
seat and thread.
(3) Tighten the bolts temporarily with tightening
torque of 44 N´m (4.5 kg-m, 33 ft-lb).
(4) Tighten the crankshaft pulley bolts.
Tightening torque:
127
±5 N´m (13.0±0.5 kg-m, 94.0±3.6 ft-lb)
B2M2586A
5) Confirm that the tightening angle of the crank-
shaft pulley bolt is 45 degrees or more. If not, con-
duct the following procedures (1) through (4).
25
[W2C4]2-3aSERVICE PROCEDURE
2. Timing Belt

4) Remove cylinder head bolts in alphabetical
sequence shown in figure.
CAUTION:
Leave bolts (a) and (c) engaged by three or four
threads to prevent cylinder head from falling.
B2M2628A
5) While tapping cylinder head with a plastic
hammer, separate it from cylinder block.
6) Remove bolts (a) and (b) to remove cylinder
head.
B2M2628A
7) Remove cylinder head gasket.
CAUTION:
Do not scratch the mating surface of cylinder
head and cylinder block.
8) Similarly, remove right side cylinder head.
41
[W5A2]2-3aSERVICE PROCEDURE
5. Cylinder Head

(5) Put new valve guide, coated with sufficient
oil, in cylinder, and insert ST1 into valve guide.
Press in until the valve guide upper end is flush
with the upper surface of ST2.
ST1 499767400 VALVE GUIDE REMOVER
Intake side:
ST2 499767700 VALVE GUIDE ADJUSTER
Exhaust side:
ST2 499767800 VALVE GUIDE ADJUSTER
B2M2632A
(6) Check the valve guide protrusion.
Valve guide protrusion: L
Intake
20.0 Ð 20.5 mm (0.787 Ð 0.807 in)
Exhaust
16.5 Ð 17.0 mm (0.650 Ð 0.669 in)
B2M0077A
(7) Ream the inside of valve guide with ST.
Gently rotate the reamer clockwise while press-
ing it lightly into valve guide, and return it also
rotating clockwise. After reaming, clean valve
guide to remove chips.
CAUTION:
IApply engine oil to the reamer when ream-
ing.
IIf the inner surface of the valve guide is torn,
the edge of the reamer should be slightly
ground with an oil stone.
IIf the inner surface of the valve guide
becomes lustrous and the reamer does not
chips, use a new reamer or remedy the reamer.
ST 499767400 VALVE GUIDE REAMER
B2M0078
(8) Recheck the contact condition between
valve and valve seat after replacing valve guide.
45
[W5C3]2-3aSERVICE PROCEDURE
5. Cylinder Head